Air-based Thermal Separation System

This disclosure relates to air distribution systems and, more particularly, to air distribution systems for use in the hot aisles of datacenters.

The history of cooling datacenters reflects the broader narrative of technological advancement and environmental awareness. In the initial stages of computer development, the heat generated by computers was relatively minimal, and simple, room-based air conditioning was often sufficient to maintain operational temperatures. However, as computers became more powerful and compact, and as datacenters started to house increasing numbers of servers, the heat generated became a significant issue, necessitating more sophisticated cooling solutions.

During the 1980s and 1990s, as the use of personal computers expanded and the internet began to take shape, datacenters grew in size and complexity. Cooling strategies evolved from simple air conditioning to more advanced computer room air conditioning (CRAC) units and computer room air handlers (CRAHs), designed specifically for datacenter environments. These systems focused on managing the airflow more efficiently, often employing raised floor systems to distribute cooled air directly to the servers.

The early 2000s marked a period of rapid growth in data processing and storage needs, driven by the dot-com boom, widespread adoption of the internet, and the beginning of cloud computing technologies. This period saw a significant increase in energy consumption by datacenters, making cooling efficiency a critical concern. Concepts such as hot aisle/cold aisle configurations, where racks are arranged to separate the hot exhaust air from the cool intake air, became standard practices to improve cooling efficiency and reduce energy consumption.

In recent years, the focus has shifted towards sustainable and energy-efficient cooling methods. Innovations such as using outside air (free cooling), especially in cooler climates or during colder months, and employing liquid cooling systems, where coolant is brought directly to the hot components, have gained popularity. These methods not only reduce energy consumption but also aim to minimize the environmental impact of datacenter operations. Additionally, the use of advanced management systems that utilize machine learning and artificial intelligence to optimize cooling based on real-time data has further enhanced efficiency.

Moreover, the industry has seen experimental and innovative approaches to datacenter cooling, including underwater datacenters, which leverage the natural cooling properties of water bodies, and building datacenters in cold locations like the Arctic. These approaches represent the cutting edge of cooling technology, showcasing the industry's ongoing efforts to balance computational demands with environmental sustainability and energy efficiency.

Overall, the history of cooling datacenters is a testament to the industry's adaptability and innovation, responding to the ever-increasing demands for data processing with creative and increasingly sustainable solutions.

In a datacenter, hot aisle containment is a cooling strategy designed to optimize airflow management and cooling efficiency. This approach involves arranging server racks in alternating rows, forming cold aisles and hot aisles. The cold aisle is where servers draw in cool air, typically supplied through raised floor plenums or overhead ductwork, while the hot aisle is where servers expel hot exhaust air. Servers within the racks are oriented to either draw in cool air from the front and expel hot air from the back, or vice versa, depending on the specific layout.

Containment structures, such as doors, panels, or overhead ducts, are used to isolate the hot aisle and prevent hot air from mixing with the cool air in the cold aisle. Precision air conditioning units or computer room air conditioners (CRACs) supply the cold air to maintain optimal temperatures within the cold aisle. By containing the hot exhaust air and supplying cool air directly to the cold aisle, hot aisle containment improves cooling efficiency, reduces energy consumption, and enhances the performance and reliability of the IT equipment housed within the datacenter.

Unfortunately and oftentimes, the waste heat from a higher-power rack-mount IT component may exhaust upon (and heat up) lower-power rack mount IT components located across the hot aisle of the datacenter.

As will be discussed below in greater detail, implementations of the present disclosure are configured to utilize an air diffuser system that is longitudinally positioned within a hot aisle of a datacenter and configured to discharge output airflow in a generally upward direction to form an essentially-planar discharge airflow that thermally isolates opposite sides of the hot aisle of a datacenter.

Referring to, there is shown an air-based thermal separation system (e.g., air-based thermal separation system) for use proximate rack-mounted IT equipment (e.g., rack-mounted IT equipmentwithin computer rack assembly).

The air-based thermal separation system (e.g., air-based thermal separation system) may include an air circulation system (e.g., air circulation system) configured to receive input air (e.g., input air) and generate an output airflow (e.g., output airflow). The air circulation system (e.g., air circulation system) may also be referred to as a cooling side unit (CSU).

The air circulation system (e.g., air circulation system) may include a fan assembly (e.g., fan assembly). The fan assembly (e.g., fan assembly) may refer to a collection of components designed to create airflow in a particular system or device. These assemblies (e.g., fan assembly) are commonly found in various applications, including electronics cooling, HVAC systems, automobiles, and industrial machinery. In electronics cooling, a fan assembly (e.g., fan assembly) often consists of a fan blade, motor, housing, and sometimes a grille or shroud, which may be used to dissipate heat generated by electronic components (e.g., computer processors or power supplies) by moving air across heat sinks or other cooling elements. And in HVAC systems, fan assemblies (e.g., fan assembly) are integral components that circulate air to maintain target temperatures and ensure adequate ventilation. Such systems may include fan blades, motors, housings, and ductwork.

The air circulation system (e.g., air circulation system) may include a mechanical cooling system (e.g., mechanical cooling system) for cooling the output airflow (e.g., output airflow). A mechanical cooling system (e.g., mechanical cooling system) may refer to the equipment and processes used to cool indoor spaces by removing heat from the air. Typically, these systems (e.g., mechanical cooling system) consist of several key components. A compressor compresses refrigerant gas, raising its temperature and pressure. This hot, high-pressure gas then flows to the condenser coil, where it dissipates heat to the surroundings and condenses into a liquid. After condensing, the refrigerant passes through an expansion valve, reducing its pressure and causing it to expand and cool down significantly. The cooled refrigerant then flows to the evaporator coil, where it absorbs heat from the indoor air, causing the refrigerant to evaporate back into a gas. A fan assembly (e.g., fan assembly) blows air over the evaporator coil, transferring heat from the air to the refrigerant. A duct system (e.g., duct system) may distribute the cooled air (e.g., output airflow).

The air circulation system (e.g., air circulation system) may be configured to be positioned within and/or proximate a computer rack assembly (e.g., computer rack assembly). A computer rack assembly (e.g., computer rack assembly) is a structured framework designed to efficiently hold and organize computer equipment (e.g., rack-mounted IT equipment) in various IT environments such as datacenters and server rooms. Its primary components include a sturdy metal frame providing structural support, horizontal rails for mounting equipment securely, and various mounting hardware like screws and cage nuts for attachment. Some assemblies feature side panels or doors to enclose the equipment, offering security and protection from environmental factors. Cable management features are often integrated to organize and route cables neatly, while ventilation options like perforated doors or built-in fans promote airflow and cooling. Additionally, power distribution units (PDUs) or power strips may be included to facilitate power management for connected equipment. These assemblies come in standard widths of 19 inches, with heights measured in rack units (U). They offer a standardized and efficient solution for organizing and managing IT equipment, catering to the diverse needs of modern computing environments.

The air-based thermal separation system (e.g., air-based thermal separation system) may include an air diffuser system (e.g., air diffuser system) configured to be longitudinally positioned (e.g., in the direction of arrow) within a hot aisle (e.g., hot aisle) of a datacenter (e.g., datacenter). An air diffuser system (e.g., air diffuser system) is a component of HVAC systems, responsible for distributing conditioned air (e.g., output airflow). These diffuser systems (e.g., air diffuser system) come in various styles and sizes to suit different airflow requirements preferences. The air diffuser system (e.g., air diffuser system) may be referred to as a flow rail. The air diffuser system (e.g., air diffuser system) may provide feedback (e.g., feedback) to the air circulation system (e.g., air circulation system) by e.g., monitoring the pressure differential between the pressure of the output airflow (e.g., output airflow) and the ambient pressure. Such a configuration may enable the air circulation system (e.g., air circulation system) to control such differential pressure by controlling the volume of the output airflow (e.g., output airflow) and the quantity of cooling provided to the air diffuser system (e.g., air diffuser system), which may be increased/decreased depending upon the quantity of waste heat generated by rack-mounted IT equipment. The quantity of air diffuser systems (e.g., air diffuser system) may be scaled (upward or downward) depending upon the waste heat generated by rack-mounted IT equipment

The air diffuser system (e.g., air diffuser system) may include: an input port (e.g., input port) for receiving the output airflow (e.g., output airflow), and an essentially-linear discharge port (e.g., essentially-linear discharge port) for discharging the output airflow (e.g., output airflow) in a generally upward direction (i.e., in the direction of arrow) to form an essentially-planar discharge airflow (e.g., essentially-planar discharge airflow). An example of such an essentially-planar discharge airflow (e.g., essentially-planar discharge airflow) may include but is not limited to an air curtain.

An air curtain (e.g., essentially-planar discharge airflow), also known as an air door, is a device used in HVAC systems to create a barrier of air. This barrier of air helps to separate two different environments, such as conditioned indoor air and outdoor air, or two differently conditioned indoor spaces, without the need for a physical door. Air curtains typically consist of a fan or blower unit (e.g., fan assembly), which generates a high-velocity stream of air (e.g., essentially-planar discharge airflow). The airflow (e.g., essentially-planar discharge airflow) creates a barrier that prevents the exchange of air between the two spaces.

The air diffuser system (e.g., air diffuser system) may be at least as long as the width of a computer rack (e.g., computer rack). The average width of a computer rack (e.g., computer rack) is standardized at 19 inches (48.26 centimeters).

This measurement is a widely adopted industry standard, ensuring compatibility across various brands and types of IT equipment designed for rack mounting. However, while 19 inches is the most common width, wider racks are also available for accommodating larger equipment or for specialized applications. It is also foreseeable that air diffuser systemmay be many feet long and configured to span multiple computer racks (e.g., computer rack).

The air diffuser system (e.g., air diffuser system) may include one or more discharge slots. For example, essentially-linear discharge portmay be/include one or more discharge slots (as shown in).

A discharge slot in an air distribution system refers to a narrow opening or slot through which conditioned air is released into a room or space. These slots are typically located along the length of a linear diffuser (e.g., air diffuser system) and are designed to provide a continuous and even distribution of airflow.

The air diffuser system (e.g., air diffuser system) may include a plurality of discharge nozzles. For example, essentially-linear discharge portmay be/include a plurality of discharge nozzles (as shown in).

In an air distribution system, a discharge nozzle refers to discrete air distribution source. Such discharge nozzles may be arranged in a linear fashion to provide a continuous and even distribution of airflow (in a fashion similar to a discharge slot.

The air diffuser system (e.g., air diffuser system) may be configured to be mounted on the floor (e.g., floor) of the datacenter (e.g., datacenter). In a datacenter, the floor (e.g., floor) serves as a crucial component of the overall infrastructure, providing structural support, cable management, airflow distribution, and cooling capabilities. Many datacenters utilize raised flooring systems consisting of removable floor panels supported by a grid of pedestals. This raised floor creates an accessible space beneath where cabling, power distribution, and cooling infrastructure can be routed and organized. Additionally, the raised floor allows for the distribution of cool air from the underfloor plenum to the equipment racks, improving airflow and cooling efficiency.

The air diffuser system (e.g., air diffuser system) may be configured to vertically separate the hot aisle (e.g., hot aisle) of the datacenter (e.g., datacenter) in a longitudinal fashion (e.g., in the direction of arrow). Specifically, the air diffuser system (e.g., air diffuser system) may be configured to upwardly redirect waste heat (e.g., waste heat,) from a rack-mounted IT component (e.g., rack-mounted IT equipment).

Accordingly and in such a configuration, air-based thermal separation systemmay prevent the waste heat from higher-power rack-mount IT components exhausting upon (and heating up) lower-power rack mount IT components located across the hot aisle (e.g., hot aisle) of datacenter, thus thermally isolating opposite sides of the hot aisle of a datacenter (e.g., datacenter).

This waste heat (e.g., waste heat,) from the rack-mounted IT component (e.g., rack-mounted IT equipment) may be collected by intake plenum, which may direct this waste heat (e.g., waste heat,) to a cooling system (not shown) for cooling datacenter. By collecting such waste heat (e.g., waste heat,) within intake plenum, such waste heat (e.g., waste heat,) may not infiltrate the cool aisles (e.g., cool aisles) of datacenter.

The rack-mounted IT component (e.g., rack-mounted IT equipment) may include a rack-mounted GPU system. A rack-mounted GPU system may be a configuration where graphics processing units (GPUs) are installed in server racks within a datacenter or server room environment. These systems are designed to harness the parallel processing power of GPUs for various computational tasks, such as high-performance computing (HPC), artificial intelligence (AI), machine learning (ML), deep learning (DL), and scientific simulations.

In a rack-mounted GPU system, multiple GPUs are typically housed within a server chassis or blade enclosure, which is then mounted in a standard server rack alongside other computing and networking equipment. These systems are often used in scenarios where high computational throughput is required, such as in scientific research, financial modeling, data analytics, and rendering for media and entertainment.

Rack-mounted GPU systems offer several advantages:

Overall, rack-mounted GPU systems are a powerful solution for organizations seeking high-performance computing capabilities for demanding workloads while optimizing space and resource utilization in their datacenters.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiment was chosen and described in order to best explain the principles of the disclosure and the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

A number of implementations have been described. Having thus described the disclosure of the present application in detail and by reference to embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the disclosure defined in the appended claims.